Polymer encased smokeless tobacco products

ABSTRACT

Methods for encasing bodies including smokeless tobacco or a tobacco substitute with a polymeric casing can include coating a compressed body with microfibers, applying tubular casings to compressed bodies, printing netting and webs on compressed bodies, injection molding around compressed bodies, applying a webbing to compressed bodies, placing compressed bodies into a skin forming bath, and including thermoplastic polymers in a compressed body.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 14/657,018filed on Mar. 13, 2015, which issued as U.S. Pat. No. 9,896,228 on Feb.20, 2018, and which claims benefit under 35 U.S.C. § 119(e) to U.S.Application No. 61/953,387 filed on Mar. 14, 2014. The disclosures ofthe prior applications are incorporated by reference in their entirety.

WORKING ENVIRONMENT

This disclosure generally relates to polymer encased smokeless tobaccoproducts, polymer encases tobacco substitute products, methods forforming polymeric casings around smokeless tobacco products and tobaccosubstitute products, and machines for encasing bodies includingsmokeless tobacco or a tobacco substitute.

Smokeless tobacco is tobacco that is placed in the mouth and notcombusted. There are various types of smokeless tobacco including:chewing tobacco, moist smokeless tobacco, snus, and dry snuff. Chewingtobacco is coarsely divided tobacco leaf that is typically packaged in alarge pouch-like package and used in a plug or twist. Moist smokelesstobacco is a moist, more finely divided tobacco that is provided inloose form or in pouch form and is typically packaged in round cans andused as a pinch or in a pouch placed between a cheek and gum of an adulttobacco consumer. Snus is a heat treated smokeless tobacco. Dry snuff isfinely ground tobacco that is placed in the mouth or used nasally.

Smokeless tobacco can be pouched in a fabric using a pouching machine.In some cases, a method for pouching smokeless tobacco includesflavoring the smokeless tobacco, pouching the flavored smokeless tobaccointo a paper or fabric, and then packaging the pouches for delivery toconsumers. A conventional pouching machine may form a supply of pouchingmaterial around tube, seal the edges of the pouching material to form atube of pouching material, form a cross-seal to form a bottom of thepouch, deliver an amount of smokeless tobacco through the tube and intothe bottom-sealed pouch, move the bottom-sealed pouch off the tube, andform a second cross-seal above the smokeless tobacco to close the pouch.The second-cross-seal can also be used as the bottom seal for asubsequent pouch as the process continues. Individual pouches can be cutat the cross-seals.

SUMMARY

Methods for encasing bodies including smokeless tobacco or a tobaccosubstitute with a polymeric casing can include coating a compressed bodywith microfibers, applying tubular casings to compressed bodies,printing netting and webs on compressed bodies, injection molding aroundcompressed bodies, applying a webbing to compressed bodies, placingcompressed bodies into a skin forming bath, and including thermoplasticpolymers in a compressed body.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the methods and compositions of matter belong. Althoughmethods and materials similar or equivalent to those described hereincan be used in the practice or testing of the methods and compositionsof matter, suitable methods and materials are described below. Inaddition, the materials, methods, and examples are illustrative only andnot intended to be limiting. All publications, patent applications,patents, and other references mentioned herein are incorporated byreference in their entirety.

DESCRIPTION OF DRAWINGS

FIG. 1 schematically depicts a method of applying and curing microfibersapplied to a body of smokeless tobacco.

FIG. 2 demonstrates an alternative way to apply microfibers to a body ofsmokeless tobacco.

FIG. 3 depicts a method of applying shrink wrap mesh tubes around acompressed body to form an encased body.

FIG. 4 depicts an alternative method for applying compression mesh tubesaround a compressed body to form an encased body.

FIG. 5 depicts a method of printing netting on sides of a compressedbody.

FIG. 6 depicts an exemplary production line used for the method of FIG.5.

FIG. 7A depicts compressed bodies positioned in a mold.

FIG. 7B depicts compressed bodies having polymeric material injectedaround them in the mold of FIG. 7A.

FIG. 8 depicts a method of applying a webbing to a compressed body.

FIG. 9A depicts an apparatus for depositing compressed bodies into abath. FIG. 9B depicts a possible porous coating. FIGS. 9C and 9D depictpotential product forms.

FIG. 10A depicts an apparatus for forming encased bodies of smokelesstobacco by combining thermoplastic fibers and smokeless tobacco materialinto a compressed body and melt bonding the thermoplastic fibers atsurface of a compressed body. FIGS. 10B and 10C depict potential productforms.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Methods and machines provided herein can form polymeric casings aroundsmokeless tobacco, tobacco substitutes, and/or similar materials (e.g.,tea). Methods and machines provided herein are adapted to provideencased smokeless tobacco products that can retain the smokeless tobaccomaterial, but provide an adult tobacco consumer with desirable flavorand tactile experience.

In some cases, methods and machines provided herein can encasecompressed bodies of smokeless tobacco, a tobacco substitute, or similarmaterial in an elastomeric polymer (e.g., polyurethane). In addition topolyurethane, other suitable elastomeric polymers suitable for methodsand machines provided herein include styrenes (including styrene blockcopolymers), EVA (ethyl vinyl acetate), and/or polyether block amides.In some cases, non-elastomeric polymers can be used in methods andmachines provided herein. Suitable non-elastomeric polymers includerayon, polypropylene, polyethylene, polyethylene terephthalate, andcellulose. In some cases, blends and/or composites of multiple polymerscan provide suitable elastomeric or non-elastomeric polymeric fiberwebs. In some cases, a blend of polyurethane, polypropylene, and styrenecan be compounded and used in casings provided herein. In some cases,cellulose mouth dissolvable fibers can be included in the body and/orcasing.

Microfiber Casing

In some cases, such as shown in FIG. 1, a casing of polymeric materialcan be produced by coating a compressed body 104 with microfibers 112and curing and/or melt bonding the microfibers with a heat source 140 toform a web encased body 108. As shown, a sticky coating or electrostaticcharge 131 can be applied to make compressed body 104 a sticky body 105.Sticky body 105 can be introduced into a chamber 110 filled withcirculating microfibers 112. While in chamber 110, the sticky body 105can become coated with microfibers 112 to become a covered body 106.Rods 122 and 124 can support bodies passed through chamber 110. Rods 122and 124 can rotate to cause the body 106 to rotate and thus become fullycovered in microfibers 112. In some cases, the rods 122 and 124 can beheated. Upon exiting the chamber, the covered body 106 can be heated tomelt bond and/or cure the microfibers into a continuous network orwebbing to form the web encased body 108. In some cases, the heat source140 can supply IR, UV, and/or convection heat. In some cases, thecompressed body 104 can have a reduced oven volatiles content during theprocess of applying the microfibers 112. In some cases, the body 104 canhave an oven volatiles of less than 60 weight percent prior to applyingthe microfibers 112, less than 50 weight percent prior to applying themicrofibers 112, less than 40 weight percent prior to applying themicrofibers 112, less than 30 weight percent prior to applying themicrofibers 112, less than 20 weight percent prior to applying themicrofibers 112, or less than 10 weight percent prior to applying themicrofibers 112. In some cases, a rewetting spray 132 can be applied toraise the oven volatiles to at least 10 weight percent, at least 20weight percent, at least 30 weight percent, at least 40 weight percent,at least 50 weight percent, or at least 60 weight percent.

FIG. 2 depicts an alternative way of coating a body 202 with microfibers212 to form a covered body 206. As shown, the body 204 can roll/tumbledown a sloping surface 210 covered with sticky microfibers 212. In somecases, the sloping surface 210 can be adapted to vibrate, which can helpconvey the body 204 down the slope and/or provide a random orientationof the fibers 212. The body 204 will accumulate sticky microfibers 212on its path down the sloping surface 210. An amount of microfibersaccumulated can be based on an amount of sticky microfibers on thesurface and the length of the sloping surface 210. The covered body 206can be cured and/or melt bonded to form a web encased body as discussedabove in reference to FIG. 1.

Mesh Casing

In some cases, such as shown in FIGS. 3 and 4, a casing of polymericmaterial can be produced by placing a compressed body 104 withinpolymeric tubes, reducing the diameter of the tubes, and melt bondingand/or curing the tubes to form a mesh encased body. Referring to FIG.3, a compressed body 304 can be placed in first mesh tube 312 a. Firstmesh tube 312 a can define a plurality of fenestrations. Once positionedin first mesh tube 312 a, the diameter of first mesh tube 312 a can bereduced. In some cases, as shown in FIG. 3, heat 342 can be applied toreduce the diameter of first mesh tube 312 a to produce partiallycovered body 306 having non-covered ends 307. Partially covered body 306can be placed in a second mesh tube 312 b such that non-covered ends 307are positioned adjacent to walls of second mesh tube 312 b. Heat 344 canagain be applied to reduce the diameter of second mesh tube 312 b, andoptionally to melt-bond the first and second mesh tubes 312 a and 312 btogether, to form mesh encased body 108. Exemplary suitable materialsfor first and second mesh tubes 312 a and 312 b include PTFE, FEP,nylon, polyolefins, neoprene, EVA (ethyl vinyl acetate), and PVC.

Referring to FIG. 4, mesh tubes can also be expanded and reduced bymechanical means. As shown in FIG. 4, first mesh tube 411 a can bemechanically expanded using force 450 that increases the diameter toform first expanded mesh tube 412 a. In some cases, expanding thediameter can reduce the length of the tube. In some cases, first meshtube 411 a can include bands and connectors that are curved such thatthey can be reversibly plastically or elastically deformed to expandmesh tube. Bands and connectors in mesh tube 411 a can definefenestrations there between. Compressed body 404 can be placed in firstexpanded mesh tube 412 a. Once positioned in first expanded mesh tube412 a, the diameter of first expanded mesh tube 412 a can be reducedusing force 452. In some cases, stretching the length of first expandedmesh tube 412 b will reduce the diameter to form partially covered body406 having uncovered ends 407. In some cases, first expanded mesh tubecan be plastically deformed by crimping the first expanded mesh tube 412b. In some cases, first expanded mesh tube 412 b is expanded elasticallyand held in an expanded state until compressed body 304 is in position.Partially covered body 406 can be placed in second expanded mesh tube412 b such that non-covered ends 407 are positioned adjacent to walls ofsecond expanded mesh tube 412 b. Force and/or shape memory 454 can beused to reduce the diameter of second expanded mesh tube 412 b to createcovered body 408. In some cases, heat can be applied to melt-bond thefirst and second mesh tubes 412 a and 412 b together. Exemplary suitablematerials for first and second mesh tubes 411 a and 412 b include PE andPP, which can be foamed.

Printed Casing

In some cases, a mesh or web casing can be printed on a compressed body.FIGS. 5 and 6 depict an example of how 3D printers can be used to covereach side of a compressed body 504 with a mesh casing. As shown, 3Dprinter heads 510 a, 510 b, and 510 c can deposit rows of polymer 512 a,512 b, and 512 c across a top surface of a body to form a partiallycovered body 505. Partially covered body 505 can be rotated 90 degreesin step 520 and 3D printer head 530 can print rows of polymer 532 acrossto the previously deposited rows of polymer to produce partially coveredbody 506. Partially covered body 506 can be cured (e.g., using UVenergy) in step 540 to create cured partially covered body 507. Curedpartially covered body 507 can be flipped in step 550 and 3D printerhead 560 can print rows of polymer 562 to form partially covered body508. Partially covered body 508 can be rotated 90 degrees in step 570and 3D printer head 580 can print rows of polymer 582 across previouslydeposited rows of polymer 562 to create covered body 509. Covered body509 can be cured (e.g., using UV energy) in step 590 to mesh cased body501.

FIG. 6 depicts how the steps of FIG. 5 can be conducted on an assemblyline. As shown, a molding device 620 can produce compressed bodies ofmaterial (e.g., smokeless tobacco) and deposit them on a conveyor 630that travels through each process shown in FIG. 5. As shown, a firstsection of the conveyor 632 deposits a mesh on five of the six sidesbefore partially covered body 506 enters a UV curing zone 634. A secondsection of the conveyor 636 applies a mesh on a last side of curedpartially covered body 507 before covered body 509 enters a second UVcuring zone 638 for a final cure. Second curing zone 638 can provide alonger cure than first curing zone 634. In some cases, first curing zone634 can provide a cure time that lasts about 10 second and second curingzone 638 can provide a cure time that lasts about 40 seconds. Oncecured, mesh cased bodies can be packaged in packaging section 640.

In some cases, spray heads can spray an elastomer (e.g., polyurethane)through hot melt nozzles onto a body. The elastomer fibers produced by ahot melt nozzle can air cool on the body to create a fiber encased body.

Injection Molded Casing

In some cases, such as shown in FIGS. 7A and 7B, compressed bodies canbe inserted into a mold with an inscribed webbing pattern, and materialinjected around the bodies. For example, recesses 710 can be formed in amold cavity adapted to receive compressed body 704. After material isinjected into the mold cavity, injection molded webbing 712 can remainon the body to form encased bodies 708. In some cases, the injectedmaterial can be a foamed material. After the pieces are ejected from themold with the injection molded webbing, each piece can be air and/orheat cured.

Web Casing

In some case, such as shown in FIG. 8, a non-woven net 812 of stickyfibers can be formed and a body 804 projected 820 at a high speedthrough the web to form an encased body 808. Net 812 can be formedbetween two pistons 810 a and 810 b by placing a sticky fiber materialbetween pistons 810 a and 810 b and retracting the pistons to form thenet 812. Net 812 can have a cob web type appearance. In some cases,encased body 808 is cured.

Foamed Skin Casing

In some cases, such as shown in FIG. 9A, a foamed skin casing can beapplied to compressed bodies by placing bodies 904 into a bath 960 on aconveyor 930. The bath 960 can include a foaming mixture that coats thebodies 904 and creates a foam skin. Possible materials includepolyurethane foam, PVC foam, Styrofoam, and combinations thereof. Forexample, polyurethane foam can be formed using carbon dioxide or anotherfood grade liquid gas as a solvent. FIG. 9B depicts a porous surface ofa foamed skin applied by the bath 960. FIGS. 9C and 9D depict possibleproduct forms 908 c and 908 d that can be formed using this process.

Integrated Polymer Mesh Casing

In some cases, such as shown in FIG. 10A, a mesh casing can be formedaround a compressed body by including a mesh forming material in thebody and selectively treating a surface of the body to create the mesh.As shown, a molding device 1020 can receive a mixture of thermoplasticpolymer 1081 and smokeless tobacco 1082 (or similar material) andcompress the mixture into a body 1001, which can be deposited on aconveyor 1030. Conveyor, moving between rollers 1032 and 1034, can movebody 1001 under curing lamps 1090 a, 1090 b, 1090 c, and 1090 d toselectively melt bond and/or cure thermoplastic polymer along exteriorsurfaces of the compressed body and thus form encased body 1008. FIGS.10B and 10C depict possible product forms 1008 b and 1008 c that can beformed using this process.

Polymeric Materials and Treatments

Casings provided herein can include any suitable polymer. Exemplarypolymers include polypropylene, polyurethane, styrene, and/orcombinations thereof. In some cases, polypropylene, polyurethane, andstyrene can also be compounded together in different ratios. In somecases, polymers can be colored to provide a moist appearance and/or havehydrophilic properties that allow for wicking performance.

In some cases, casings provided herein include elastomeric polymers(e.g., polyurethane). Elastomeric polymers can provide mesh and webcasings with improved elongation and toughness. In some cases, casingsprovided herein can provide the unique property of allowing an adulttobacco consumer to reduce or increase a packing density of an encasedsmokeless tobacco product, which can impact a rate of flavor release. Ahigher packing density can reduce a rate of flavor release. Suitableelastomeric polymers include EPAMOULD (Epaflex), EPALINE (Epaflex),TEXIN (Bayer), DESMOPAN (Bayer), HYDROPHAN (AdvanceSourse Biomaterials),ESTANE (Lubrizol), PELLETHANE (Lubrizol), PEARLTHANE (Merquinsa),IROGRAN (Huntsman), ISOTHANE (Greco), ZYTHANE (Alliance Polymers andServices), VISTAMAX (ExxonMobil), and MD-6717 (Kraton). In some cases,elastomers can be combined with polyolefins at ratios ranging from 1:9to 9:1. For example, elastomeric polymers can be combined withpolypropylene. In some cases, a blend of polyurethane, polypropylene,and styrene can be compounded and used in methods and machines providedherein.

Tobacco

Smokeless tobacco is tobacco suitable for use in an orally-used tobaccoproduct. By “smokeless tobacco” it is meant a part, e.g., leaves, andstems, of a member of the genus Nicotiana that has been processed.Exemplary species of tobacco include N. rustica, N tabacum, N.tomentosiformis, and N. sylvestris. Suitable tobaccos include fermentedand unfermented tobaccos. In addition to fermentation, the tobacco canalso be processed using other techniques. For example, tobacco can beprocessed by heat treatment (e.g., cooking, toasting), flavoring, enzymetreatment, expansion and/or curing. Both fermented and non-fermentedtobaccos can be processed using these techniques. In other embodiments,the tobacco can be unprocessed tobacco. Specific examples of suitableprocessed tobaccos include, dark air-cured, dark fire-cured, burley,flue cured, and cigar filler or wrapper, as well as the products fromthe whole leaf stemming operation. In some cases, smokeless tobaccoincludes up to 70% dark tobacco on a fresh weight basis.

Tobacco can be conditioned by heating, sweating and/or pasteurizingsteps as described in U.S. Publication Nos. 2004/0118422 or2005/0178398. In addition to modifying the aroma of the leaf,fermentation can change the color, texture, and other sensorialattributes (taste) of a leaf. Also during the fermentation process,evolution gases can be produced, oxygen can be taken up, the pH canchange, and the amount of water retained can change. See, for example,U.S. Publication No. 2005/0178398 and Tso (1999, Chapter 1 in Tobacco,Production, Chemistry and Technology, Davis & Nielsen, eds., BlackwellPublishing, Oxford). Cured, or cured and fermented tobacco can befurther processed (e.g., cut, expanded, blended, milled or comminuted)prior to incorporation into the smokeless tobacco product. The tobacco,in some cases, is long cut fermented cured moist tobacco having an ovenvolatiles content of between 30 and 61 weight percent prior to mixingwith the polymeric material and optionally flavorants and otheradditives.

The tobacco can, in some cases, be prepared from plants having less than20 μg of DVT per cm² of green leaf tissue. For example, the tobaccoparticles can be selected from the tobaccos described in U.S. PatentPublication No. 2008/0209586, which is hereby incorporated by reference.Tobacco compositions containing tobacco from such low-DVT varietiesexhibits improved flavor characteristics in sensory panel evaluationswhen compared to tobacco or tobacco compositions that do not havereduced levels of DVTs.

Green leaf tobacco can be cured using conventional means, e.g.,flue-cured, barn-cured, fire-cured, air-cured or sun-cured. See, forexample, Tso (1999, Chapter 1 in Tobacco, Production, Chemistry andTechnology, Davis & Nielsen, eds., Blackwell Publishing, Oxford) for adescription of different types of curing methods. Cured tobacco isusually aged in a wooden drum (i.e., a hogshead) or cardboard cartons incompressed conditions for several years (e.g., two to five years), at amoisture content ranging from 10% to about 25%. See, U.S. Pat. Nos.4,516,590 and 5,372,149. Cured and aged tobacco then can be furtherprocessed. Further processing includes conditioning the tobacco undervacuum with or without the introduction of steam at varioustemperatures, pasteurization, and fermentation. Cure, aged, andfermented smokeless tobacco can be further processed (e.g., cut,shredded, expanded, or blended). See, for example, U.S. Pat. Nos.4,528,993; 4,660,577; and 4,987,907.

The smokeless tobacco can be processed to a desired size. For example,long cut smokeless tobacco typically is cut or shredded into widths ofabout 10 cuts/inch up to about 110 cuts/inch and lengths of about 0.1inches up to about 1 inch. Double cut smokeless tobacco can have a rangeof particle sizes such that about 70% of the double cut smokelesstobacco falls between the mesh sizes of −20 mesh and 80 mesh. Otherlengths and size distributions are also contemplated.

The smokeless tobacco can have a total oven volatiles content of about10% by weight or greater; about 20% by weight or greater; about 40% byweight or greater; about 15% by weight to about 25% by weight; about 20%by weight to about 30% by weight; about 30% by weight to about 50% byweight; about 45% by weight to about 65% by weight; or about 50% byweight to about 60% by weight. Those of skill in the art will appreciatethat “moist” smokeless tobacco typically refers to tobacco that has anoven volatiles content of between about 30% by weight and about 61% byweight (e.g., about 45% by weight to about 55% by weight, or about 50%by weight). As used herein, “oven volatiles” are determined bycalculating the percentage of weight loss for a sample after drying thesample in a pre-warmed forced draft oven at 110° C. for 3.25 hours. Theencased smokeless tobacco product can have a different overall ovenvolatiles content than the oven volatiles content of the smokelesstobacco used to make the encased smokeless tobacco product. Theprocessing steps described herein can reduce or increase the ovenvolatiles content. The overall oven volatiles content of the encasedsmokeless tobacco product is discussed below.

The encased smokeless tobacco product can include between 15 weightpercent and 85 weight percent smokeless tobacco on a dry weight basis.The amount of smokeless tobacco in encased smokeless tobacco product ona dry weight basis is calculated after drying the product in apre-warmed forced draft oven at 110° C. for 3.25 hours. The remainingnon-volatile material is then separated into tobacco material andpolymeric material. The percent smokeless tobacco in the encasedsmokeless tobacco product is calculated as the weight smokeless tobaccodivided by the total weight of the non-volatile materials. In somecases, the encased smokeless tobacco product includes between 20 and 60weight percent tobacco on a dry weight basis. In some cases, the encasedsmokeless tobacco product includes at least 28 weight percent tobacco ona dry weight basis. In some cases, enrobed product portions produced inmethods and/or machines provided herein can be rewet with water and/or asolution of flavorants, sweeteners, and/or other additives discussedherein to wick the coating of polymeric fibers, provide a moistappearance, prove a flavor immediately, and/or to increase a flavorintensity.

In some cases, a plant material other than tobacco is used as a tobaccosubstitute in the pouched products made using machines and methodsprovided herein. The tobacco substitute can be an herbal composition.Herbs and other edible plants can be categorized generally as culinaryherbs (e.g., thyme, lavender, rosemary, coriander, dill, mint,peppermint) and medicinal herbs (e.g., Dahlias, Cinchona, Foxglove,Meadowsweet, Echinacca, Elderberry, Willow bark). In some cases, thetobacco is replaced with a mixture of non-tobacco plant material. Suchnon-tobacco compositions may have a number of different primaryingredients, including but not limited to, tea leaves, red clover,coconut flakes, mint leaves, ginseng, apple, corn silk, grape leaf, andbasil leaf. The plant material typically has a total oven volatilescontent of about 10% by weight or greater; e.g., about 20% by weight orgreater; about 40% by weight or greater; about 15% by weight to about25% by weight; about 20% by weight to about 30% by weight; about 30% byweight to about 50% by weight; about 45% by weight to about 65% byweight; or about 50% by weight to about 60% by weight.

Flavorants and Additives

Flavors and other additives can be included in the compositions andarrangements described herein and can be added to the encased smokelesstobacco product at any point in the process. For example, any of theinitial components, including the polymeric material, can be provided ina flavored form. In some cases, flavorants and/or other additives areincluded in the smokeless tobacco. In some cases, flavorants and/orother additives are absorbed into to the encased smokeless tobaccoproduct after pouching. In some cases, flavorants and/or other additivesare mixed with the polymeric material (e.g., with structural fibers)prior to melt-blowing the fibers and/or as the fibers exit thespinnerets.

Suitable flavorants include wintergreen, cherry and berry typeflavorants, various liqueurs and liquors such as Drambuie, bourbon,scotch, whiskey, spearmint, peppermint, lavender, cinnamon, cardamom,apium graveolens, clove, cascarilla, nutmeg, sandalwood, bergamot,geranium, honey essence, rose oil, vanilla, lemon oil, orange oil,Japanese mint, cassia, caraway, cognac, jasmine, chamomile, menthol,ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee,liquorish, and mint oils from a species of the genus Mentha. Mint oilsuseful in particular embodiments of the encased smokeless tobaccoproducts include spearmint and peppermint.

Flavorants can also be included in the form of flavor beads, which canbe dispersed within the encased smokeless tobacco product (e.g., in anonwoven network of polymeric structural fibers). For example, theencased smokeless tobacco product could include the beads described inU.S. Patent Application Publication 2010/0170522, which is herebyincorporated by reference.

In some cases, the amount of flavorants in the encased smokeless tobaccoproduct is limited to less than 30 weight percent in sum. In some cases,the amount of flavorants in the encased smokeless tobacco product can belimited to be less than 5 weight percent in sum. For example, certainflavorants can be included in the encased smokeless tobacco product inamounts of about 3 weight percent.

Other optional additives can include but are not limited to fillers(e.g., starch, dicalcium phosphate, lactose, sorbitol, mannitol, andmicrocrystalline cellulose), soluble fiber (e.g., Fibersol fromMatsushita), calcium carbonate, dicalcium phosphate, calcium sulfate,and clays), sodium chloride, lubricants (e.g., lecithin, stearic acid,hydrogenated vegetable oil, mineral oil, polyethylene glycol 4000-6000(PEG), sodium lauryl sulfate (SLS), glyceryl palmitostearate, sodiumbenzoate, sodium stearyl fumarate, talc, and stearates (e.g., Mg or K),and waxes (e.g., glycerol monostearate, propylene glycol monostearate,and acetylated monoglycerides)), plasticizers (e.g., glycerine,propylene glycol, polyethylene glycol, sorbitol, mannitol, triacetin,and 1,3 butane diol), stabilizers (e.g., ascorbic acid and monosterolcitrate, BHT, or BHA), artificial sweeteners (e.g., sucralose,saccharin, and aspartame), disintegrating agents (e.g., starch, sodiumstarch glycolate, cross caramellose, cross linked PVP), pH stabilizers,or other compounds (e.g., vegetable oils, surfactants, andpreservatives). Some compounds display functional attributes that fallinto more than one of these categories. For example, propylene glycolcan act as both a plasticizer and a lubricant and sorbitol can act asboth a filler and a plasticizer.

Oven volatiles, such as water, may also be added to the encasedsmokeless tobacco product to bring the oven volatiles content of theencased smokeless tobacco product into a desired range. In some cases,flavorants and other additives are included in a hydrating liquid.

Oven Volatiles

The encased smokeless tobacco product can have a total oven volatilescontent of between 10 and 61 weight percent. In some cases, the totaloven volatiles content is at least 40 weight percent. The oven volatilesinclude water and other volatile compounds, which can be a part of thetobacco, the polymeric material, the flavorants, and/or other additives.As used herein, the “oven volatiles” are determined by calculating thepercentage of weight loss for a sample after drying the sample in apre-warmed forced draft oven at 110° C. for 3.25 hours. Some of theprocesses may reduce the oven volatiles content (e.g., heating thecomposite or contacting the smokeless tobacco with a heated polymericmaterial), but the processes can be controlled to have an overall ovenvolatiles content in a desired range. For example, water and/or othervolatiles can be added back to the encased smokeless tobacco product tobring the oven volatiles content into a desired range. In some cases,the oven volatiles content of the composite encased smokeless tobaccoproduct is between 50 and 61 weight percent. For example, the ovenvolatiles content of smokeless tobacco used in the various processeddescribed herein can be about 57 weight percent. In other embodiments,the oven volatiles content can be between 10 and 30 weight percent.

OTHER EMBODIMENTS

It is to be understood that, while the invention has been describedherein in conjunction with a number of different aspects, the foregoingdescription of the various aspects is intended to illustrate and notlimit the scope of the invention, which is defined by the scope of theappended claims. Other aspects, advantages, and modifications are withinthe scope of the following claims.

Disclosed are methods and compositions that can be used for, can be usedin conjunction with, can be used in preparation for, or are products ofthe disclosed methods and compositions. These and other materials aredisclosed herein, and it is understood that combinations, subsets,interactions, groups, etc. of these methods and compositions aredisclosed. That is, while specific reference to each various individualand collective combinations and permutations of these compositions andmethods may not be explicitly disclosed, each is specificallycontemplated and described herein. For example, if a particularcomposition of matter or a particular method is disclosed and discussedand a number of compositions or methods are discussed, each and everycombination and permutation of the compositions and the methods arespecifically contemplated unless specifically indicated to the contrary.Likewise, any subset or combination of these is also specificallycontemplated and disclosed.

What is claimed is:
 1. A method of making a polymer encased smokelesstobacco or tobacco substitute product, the method comprising: forming acompressed body including smokeless tobacco, a tobacco substitute, orboth the smokeless tobacco and the tobacco substitute; applying anelectrostatic charge to the compressed body to form a charged body;coating the charged body with microfibers to form a microfiber-coatedbody, the microfibers including a polymeric material; and heating themicrofiber-coated body to melt bond the microfibers to form an encasedbody.
 2. The method of claim 1, wherein the coating the charged bodywith microfibers is performed in a chamber having circulatingmicrofibers.
 3. The method of claim 2, wherein the coating the chargedbody with microfibers comprises: carrying the charged body through thechamber on a conveyor.
 4. The method of claim 3, wherein the coating thecharged body with microfibers comprises: rotating, using the conveyor,the charged body.
 5. The method of claim 4, wherein the conveyorcomprises at least two rods.
 6. The method of claim 1, wherein thecoating the charged body with microfibers comprises: rolling, tumbling,or both rolling and tumbling the charged body down a sloped surface, themicrofibers being disposed on the surface.
 7. The method of claim 6,wherein the coating the charged body with microfibers further comprises:vibrating the surface during the rolling, the tumbling, or both therolling and the tumbling the charged body down the surface.
 8. Themethod of claim 1, wherein the charged body has less than about 10weight percent oven volatiles during coating the charged body withmicrofibers.
 9. The method of claim 8, further comprising: hydrating theencased body to form an encased product having greater than about 10weight percent oven volatiles.
 10. The method of claim 1, wherein theheating the microfiber-coated body includes exposing themicrofiber-coated body to infrared (IR), ultraviolet (UV), convectionheat, or combinations thereof.
 11. The method of claim 1, wherein thepolymeric material is selected from the group consisting of:polypropylene, polyurethane, styrene, and combinations thereof.
 12. Themethod of claim 1, wherein the polymeric material includes an elastomerand a polyolefin.
 13. The method of claim 1, wherein the compressed bodyfurther comprises a flavorant comprising wintergreen, cherry, berry,Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender,cinnamon, cardamom, apium graveolens, clove, cascarilla, nutmeg,sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemonoil, orange oil, Japanese mint, cassia, caraway, cognac, jasmine,chamomile, menthol, ylang-ylang, sage, fennel, piment, ginger, anise,coriander, coffee, liquorish, mint oils from a species of the genusMentha, a sub-combination thereof, or a combination thereof.